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FOLGERS

Overview

Folgers consolidated their coffee operations from Kansas City, KS and Sherman, TX to New Orleans, LA to defray shipping costs.

Project Highlights

This project was a consolidation and included the relocation and installation of 12 coffee roasters, 4 packaging lines and blending and grinding equipment from their Kansas City facility as well as coffee silos from a facility in Sherman, TX.

Areas of the existing facility were renovated to create a new plant entrance, amenities and better GMP controlled access to the operation.

An existing section of the facility was removed and a 140 foot tall 50,000 square foot processing tower was constructed.

This project included the addition of utility infrastructure (aspiration, compressed air, tower water, chilled water, and fire quenching systems), as well as a separate flavor storage building with automated delivery and cleaning systems to support the production lines.

Construction and installation was executed without impact to the plant’s existing operation, and the shutdown, relocation and startup of assets from the Kansas City facility was completed without impact to the supply of product to customers.

DREYER’S

Overview

When Dreyer’s combined its ice cream business with that of Nestlé’s, expansion of East Coast manufacturing and distribution capacity was one of the highest priorities in rationalizing the merger. Dennis Group was selected as a partner for the evaluation and execution of this major facility and process expansion project.

Project Highlights

The project involved acquiring and re-zoning 40 acres of property, increasing the size of the facility six fold to over 600,000 SF, creating a 23,000 pallet minus 20 degree distribution center, and adding 10 new ice cream and frozen yogurt lines.

This major undertaking was affected over a two year construction period, and was accomplished without sacrificing a single minute of the existing facility’s available capacity.